Phase separator for a sealed system

ABSTRACT

A sealed system is provided. The sealed system includes a compressor and a phase separator disposed downstream of the compressor. The phase separator includes a casing that defines a liquid refrigerant collection volume and a gaseous refrigerant collection volume. A refrigerant inlet conduit extends between the compressor and the gaseous refrigerant collection volume, a gaseous refrigerant outlet conduit has an inlet positioned within the gaseous refrigerant collection volume of the casing and a liquid refrigerant outlet conduit has an inlet positioned within the liquid refrigerant collection volume of the casing. A plurality of cooling fins is positioned on an outer surface of the casing. A related refrigerator appliance is also provided.

FIELD OF THE INVENTION

The present subject matter relates generally to refrigerator appliances and sealed systems, e.g., for refrigerator appliances.

BACKGROUND OF THE INVENTION

Certain refrigerator appliances include dual evaporator refrigeration systems. The dual evaporators can be useful for removing heat from two different locations within the refrigerator appliances. For example, a refrigeration loop can be provided that uses one evaporator to remove heat from a fresh food compartment and another evaporator to remove heat from a frozen food compartment. Such dual evaporator systems can be useful, e.g., to avoid temperature and/or humidity gradients that can occur with single evaporator refrigeration systems.

Dual evaporator refrigeration systems are generally more costly and complex than single evaporator refrigeration systems. Dual evaporator refrigeration systems can also incur cycling losses when switching operation from the fresh food evaporator to the freezer evaporator. Evaporators in dual evaporator refrigeration systems can also be relatively large, which can impact the energy efficiency of the appliance in which the dual evaporator refrigeration system resides. Some dual evaporator refrigeration systems also utilize dual compressors, which further increases energy usage and inefficiency. Thus, a dual evaporator refrigeration system that is relatively compact or small and has a single compressor would be useful, e.g., provide savings in costs and efficiency.

When a refrigeration system is charged, small amounts of water, such as water vapor, may be inadvertently sealed within the refrigeration system. The presence of water in the refrigeration system is deleterious to operation of the refrigeration system. Certain refrigeration systems include a drier to remove moisture from refrigerant within the refrigeration system. The drier is generally a separate component of the refrigeration system, but providing the drier as a separate component adds cost to the refrigeration system and consumes space within the associated appliance that is already crowded and needed for other components. Accordingly, a drier that is compact and/or can be provided as part of another component of a refrigeration system within an appliance would be useful.

BRIEF DESCRIPTION OF THE INVENTION

The present subject matter provides a sealed system. The sealed system includes a compressor and a phase separator disposed downstream of the compressor. The phase separator includes a casing that defines a liquid refrigerant collection volume and a gaseous refrigerant collection volume. A refrigerant inlet conduit extends between the compressor and the gaseous refrigerant collection volume, a gaseous refrigerant outlet conduit has an inlet positioned within the gaseous refrigerant collection volume of the casing and a liquid refrigerant outlet conduit has an inlet positioned within the liquid refrigerant collection volume of the casing. A plurality of cooling fins is positioned on an outer surface of the casing. A related refrigerator appliance is also provided. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In a first exemplary embodiment, a sealed system is provided. The sealed system circulates a refrigerant therein and includes a compressor and a phase separator disposed downstream of the compressor. The phase separator includes a casing having a top portion and a bottom portion. The casing defines a liquid refrigerant collection volume at the bottom portion of the casing and a gaseous refrigerant collection volume at the top portion of the casing. The casing also has an outer surface. A refrigerant inlet conduit extends between the compressor and the gaseous refrigerant collection volume. A gaseous refrigerant outlet conduit has an inlet positioned within the gaseous refrigerant collection volume of the casing. A liquid refrigerant outlet conduit has an inlet positioned within the liquid refrigerant collection volume of the casing. A plurality of cooling fins is positioned on the outer surface of the casing at the top portion of the casing.

In a second exemplary embodiment, a refrigerator appliance is provided. The refrigerator appliance includes a cabinet that defines a freezer chamber and a fresh food chamber. A sealed system is configured for cooling the freezer chamber and the fresh food chamber. The sealed system includes a compressor. A phase separator is disposed downstream of the compressor. The phase separator includes a casing having a top portion and a bottom portion. The casing defines a liquid refrigerant collection volume at the bottom portion of the casing and a gaseous refrigerant collection volume at the top portion of the casing. The casing also has an outer surface. A refrigerant inlet conduit extends between the compressor and the gaseous refrigerant collection volume. The phase separator also includes a gaseous refrigerant outlet conduit and a liquid refrigerant outlet conduit. A plurality of cooling fins is positioned on the outer surface of the casing at the top portion of the casing. A condenser is disposed downstream of the phase separator. The gaseous refrigerant outlet conduit extends between the gaseous refrigerant collection volume of the casing and the condenser. A first expansion device is disposed downstream of the condenser such that the condenser is in fluid communication with the first expansion device. The first expansion device is configured for reducing a pressure of refrigerant therein. A freezer evaporator is positioned adjacent the freezer chamber of the cabinet and disposed downstream of the first expansion device such that the first expansion device is in fluid communication with the freezer evaporator. A second expansion device is also disposed downstream of the phase separator. The liquid refrigerant outlet conduit extends between the liquid refrigerant collection volume of the casing and the second expansion device. A fresh food evaporator is positioned adjacent the fresh food chamber of the cabinet and disposed downstream of the second expansion device such that the second expansion device is in fluid communication with the fresh food evaporator.

In a third exemplary embodiment, a method for operating a sealed system is provided. The method includes operating a compressor of the sealed system to increase a pressure of a refrigerant, directing compressed refrigerant from the compressor of the sealed system to a phase separator of the sealed system, partially condensing refrigerant within the phase separator of the sealed system, collecting liquid refrigerant within a liquid refrigerant collection volume of the phase separator and gaseous refrigerant within a gaseous refrigerant collection volume of the phase separator, directing liquid refrigerant from the liquid refrigerant collection volume of the phase separator to an expansion device of the sealed system and directing gaseous refrigerant from the gaseous refrigerant collection volume of the phase separator to a condenser of the sealed system.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a front, elevation view of an exemplary embodiment of a refrigerator appliance.

FIG. 2 provides a schematic view of a sealed system according to an exemplary embodiment of the present subject matter.

FIG. 3 provides a schematic view of a phase separator according to an exemplary embodiment of the present subject matter.

FIG. 4 provides a schematic view of a phase separator according to another exemplary embodiment of the present subject matter.

FIG. 5 provides a schematic view of a phase separator according to an additional exemplary embodiment of the present subject matter.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 provides a front, elevation view of a refrigerator appliance 10 according to an exemplary embodiment of the present subject matter. More specifically, for illustrative purposes, the present subject matter is described with refrigerator appliance 10 having a construction as shown and described further below. As used herein, “refrigerator appliance” includes appliances such as a refrigerator/freezer combination, side-by-side, bottom mount, compact, and any other style or model of refrigerator appliance. Accordingly, other configurations including multiple and different styled compartments could be used with refrigerator appliance 10, it being understood that refrigerator appliance 10 shown in FIG. 1 is provided by way of example only. Additionally, the refrigeration system of the present subject matter is not limited to a refrigerator appliance and can be used in other applications where dual evaporators are desirable as well such as e.g., where separate cooling at two or more locations is desired.

Refrigerator appliance 10 includes a fresh food storage compartment 12 and a freezer storage compartment 14. Freezer compartment 14 and fresh food compartment 12 are arranged side-by-side within an outer case 16 and defined by inner liners 18 and 20 therein. A space between case 16 and liners 18 and 20, and between liners 18 and 20, is filled with foamed-in-place insulation. Outer case 16 normally is formed by folding a sheet of a suitable material, such as pre-painted steel, into an inverted U-shape to form the top and side walls of case 16. A bottom wall of case 16 normally is formed separately and attached to the case side walls and to a bottom frame that provides support for refrigerator appliance 10. Inner liners 18 and 20 are molded from a suitable plastic material to form freezer compartment 14 and fresh food compartment 12, respectively. Alternatively, liners 18, 20 may be formed by bending and welding a sheet of a suitable metal, such as steel.

A breaker strip 22 extends between a case front flange and outer front edges of liners 18, 20. Breaker strip 22 is formed from a suitable resilient material, such as an extruded acrylo-butadiene-styrene based material (commonly referred to as ABS). The insulation in the space between liners 18, 20 is covered by another strip of suitable resilient material, which also commonly is referred to as a mullion 24. In one embodiment, mullion 24 is formed of an extruded ABS material. Breaker strip 22 and mullion 24 form a front face, and extend completely around inner peripheral edges of case 16 and vertically between liners 18, 20. Mullion 24, insulation between compartments, and a spaced wall of liners separating compartments, sometimes are collectively referred to herein as a center mullion wall 26. In addition, refrigerator appliance 10 includes shelves 28 and slide-out storage drawers 30, sometimes referred to as storage pans, which normally are provided in fresh food compartment 12 to support items being stored therein.

Refrigerator appliance 10 can be operated by one or more controllers (not shown) or other processing devices according to programming and/or user preference via manipulation of a control interface 32 mounted e.g., in an upper region of fresh food compartment 12 and connected with the controller. The controller may include one or more memory devices and one or more microprocessors, such as a general or special purpose microprocessor operable to execute programming instructions or micro-control code associated with the operation of the refrigerator. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. As used herein, “controller” includes the singular and plural forms. Alternatively, the controller may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.

The controller may be positioned in a variety of locations throughout refrigerator appliance 10. In the illustrated embodiment, the controller may be located e.g., behind an interface panel 32 or doors 42 or 44. Input/output (“I/O”) signals may be routed between the control system and e.g., temperature sensors 52 and 54 as well as various operational components of refrigerator appliance 10. These signals can be provided along wiring harnesses that may be routed through e.g., the back, sides, or mullion 24. Typically, through user interface panel 32, a user may select various operational features and modes and monitor the operation of refrigerator appliance 10. In one embodiment, the user interface panel may represent a general purpose I/O (“GPIO”) device or functional block. In one embodiment, the user interface panel 32 may include input components, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface panel 32 may include a display component, such as a digital or analog display device designed to provide operational feedback to a user. The user interface panel may be in communication with the controller via one or more signal lines or shared communication busses.

A shelf 34 and wire baskets 36 are also provided in freezer compartment 14. In addition, an ice maker 38 may be provided in freezer compartment 14. A freezer door 42 and a fresh food door 44 close access openings to freezer and fresh food compartments 14, 12, respectively. Each door 42, 44 is mounted to rotate about its outer vertical edge between an open position, as shown in FIG. 1, and a closed position (not shown) closing the associated storage compartment. Freezer door 42 includes a plurality of storage shelves 46, and fresh food door 44 includes a plurality of storage shelves 48. Refrigerator appliance 10 includes a machinery compartment that incorporates at least part of a sealed refrigeration system, such as sealed refrigeration system 200 (FIG. 2).

FIG. 2 provides a schematic view of refrigeration system 200 according to an exemplary embodiment of the present subject matter. Refrigeration system 200 includes a first evaporator 212 and a second evaporator 214. By way of example, first evaporator 212 may be positioned adjacent and used to a cool freezer compartment 14 (FIG. 1) and second evaporator 214 may be positioned adjacent and used to cool fresh food compartment 12 (FIG. 1). A fresh food fan 218 is operable to circulate air in fresh food compartment 12, e.g., over and/or across first evaporator 212. Similarly, a freezer fan 216 is operable to circulate air in freezer compartment 14, e.g., over and/or across second evaporator 214. Alternatively, refrigeration system 200 may be used in other appliances where e.g., first and second evaporators 212 and 214 are positioned in different locations where cooling to different temperatures is desired.

Refrigeration system 200 includes a circulating refrigerant such as e.g., R-12, R-22, R-134a and R-600a. While certain older refrigerants are being phased out and replaced by environmentally-friendlier compounds, it is to be understood that the principles of the present subject matter are not limited to any particular refrigerant. In certain exemplary embodiments, refrigeration system 200 may be charged with a zeotropic refrigerant mixture, which is a mixture of two or more refrigerants that have different saturated liquid temperatures at the same pressure. Consequently, the concentrations of the individual refrigerants between the liquid and vapor phases are typically different when the refrigerant mixture is vaporized or boiled. In addition, zeotropic refrigerant mixtures typically exhibit temperature glide, such that the saturated liquid temperature of the zeotropic refrigerant changes as the relative compositions of refrigerants in the liquid mixture changes during vaporization.

Examples of non-flammable refrigerants that can be used in a zeotropic mixture include, but are not limited, to R-134a, R245fa, R245ca and small amounts of R-600, R-600a or R-1234yf. Examples of refrigerants that may be used in a zeotropic mixture with low Global Warming Potential (GWP) include R-600, R-600a, pentane, R290 and R-1234yf. Different mixture percentages of such refrigerants can be used in refrigeration system 200 as well. In one embodiment, the zeotropic refrigerant includes two or more refrigerants selected from a group consisting of an R-134a refrigerant, an R-245fa refrigerant, an R-245ca refrigerant, an R-1234yf refrigerant, an R-600a refrigerant, pentane, butane, and propane. As a particular example, refrigeration system 200 may be charged with a zeotropic refrigerant mixture of about 33.3% R-134a and about 66.7% R-245fa (i.e., a percent ratio of 33.3/66.7) at charging.

As shown in FIG. 2, circulating refrigerant from an inlet refrigerant flow 239 enters a compressor 202. Refrigerant may enter compressor 202 in a thermodynamic state known as a “superheated vapor.” Compressor 202 may increase a pressure of refrigerant therein and may also increase a temperature of the refrigerant as well. Relatively hot, compressed refrigerant in vapor form exits compressor 202 as a superheated vapor, but the refrigerant exiting compressor 202 is also at a temperature and pressure at which the refrigerant can be condensed with cooling water or cooling air, such as ambient atmosphere. Hot vapor refrigerant flow 248 from compressor 202 is routed to a phase separator 222.

Phase separator (e.g., and drying device) 222 is configured to receive the hot vapor refrigerant flow 248 from compressor 202. Thus, phase separator 222 is disposed downstream of compressor 202 and is in fluid communication with compressor 202 in order to receive the hot vapor refrigerant flow 248 from compressor 202. Within phase separator 222, hot vapor refrigerant from compressor 202 is cooled and partially condensed to form a liquid and vapor refrigerant mixture. Phase separator 222 separates the liquid and vapor refrigerant mixture within phase separator 222 into two phases, i.e., liquid and vapor. After being separated within phase separator 222, the vapor refrigerant and liquid refrigerant are directed to separate components of refrigeration system 200, as discussed in greater detail below.

If refrigeration system 200 is charged with a zeotropic refrigerant mixture, the stream of liquid refrigerant exiting phase separator 222 may have a different composition than the steam of vapor refrigerant exiting phase separator 222. For example, if the zeotropic refrigerant mixture includes a mixture of R-134A and R-245fa, the stream of liquid refrigerant exiting phase separator 222 may have a different ratio of R-134a to R-245fa than the steam of vapor refrigerant exiting phase separator 222. In particular, the steam of liquid refrigerant exiting phase separator 222 may have more of the lower vapor saturation temperature refrigerant (e.g., R-245fa), and the stream of vapor refrigerant exiting phase separator 222 may have more of the higher vapor saturation temperature refrigerant (e.g., R-134a).

As may be seen in FIG. 2, a vapor refrigerant flow 224 from phase separator 222 is directed to a condenser 204. Thus, condenser 204 is disposed downstream of phase separator 222 and is in fluid communication with phase separator 222, e.g., such that condenser 204 is configured to receive pressurized vapor refrigerant from phase separator 222. By way of example, vapor refrigerant flow 224 may be zeotropic refrigerant mixture of R-134a and R-245fa that exits phase separator 222 as about 82% R-134a and about 18% R-245fa (i.e., a percent ratio of 82/18), at a temperature of about 99 degrees (Fahrenheit).

In condenser 204, vapor refrigerant flow 224 is cooled and condensed into a liquid refrigerant flow 221 by flowing through a coil or tubes with relatively cooler water or cooler air flowing across such coil or tubes of condenser 204 to receive heat from the refrigerant. By way of example, such relatively cooler air may typically be air in a room or structure in which refrigerator appliance 10 operates. A fan (not shown) can be used to provide a flow of air across condenser 204. Thus, using condenser 204, circulating refrigerant rejects heat from refrigeration system 200 to e.g., water, air or other heat transfer medium.

A first reducing device 206 (also referred to as a first reducer or first expansion device) is configured to receive liquid refrigerant flow 221 from condenser 204. Thus, first reducing device 206 is disposed downstream of condenser 204 and is in fluid communication with condenser 204, e.g., such that first reducing device 206 is configured to receive liquid refrigerant flow 221 from condenser 204. In one exemplary embodiment, first reducing device 206 may be a capillary tube. Within first reducing device 206, circulated refrigerant undergoes an abrupt reduction in pressure that may result in the evaporation of a part of the liquid refrigerant flow 221. Such evaporation generally lowers the temperature of the liquid and vapor refrigerant mixture to a temperature relatively colder than the temperature of freezer compartment 14. A refrigerant flow 230 is provided from first reducing device 206 to first evaporator 212. Within first evaporator 212, refrigerant vaporizes to cool freezer compartment 14 of refrigerator appliance 10.

As may be seen in FIG. 2, a liquid refrigerant flow 234 from phase separator 222 is directed to a second reducing device 210, e.g., simultaneously with vapor refrigerant flow 224 from phase separator 222 to condenser 204. Thus, second reducing device 210 is disposed downstream of phase separator 222 and is in fluid communication with phase separator 222, e.g., such that second reducing device 210 is configured to receive pressurized liquid refrigerant from phase separator 222. By way of example, liquid refrigerant flow 234 may be zeotropic refrigerant mixture of R-134a and R-245fa that exits phase separator 222 as about 45% R-134a and about 55% R-245fa (i.e., a percent ratio of 45/55), at a temperature of about 105 degrees (Fahrenheit). In one exemplary embodiment, second reducing device 210 may be a capillary tube. Within second reducing device 210, circulated refrigerant undergoes an abrupt reduction in pressure that may result in the evaporation of a part of the liquid refrigerant flow 234. Such evaporation generally lowers the temperature of the liquid and vapor refrigerant mixture to a temperature relatively colder than the temperature of fresh food compartment 12. A refrigerant flow 236 is provided from second reducing device 210 to second evaporator 214. Within second evaporator 214, refrigerant vaporizes to cool fresh food compartment 12 of refrigerator appliance 10.

For freezer compartment 14, freezer fan 216 circulates relatively warmer air in freezer compartment 14 across a coil or tubes of second evaporator 214 that carries relatively colder refrigerant liquid and vapor mixture. Similarly, for fresh food compartment 12, fresh food fan 218 circulates relatively warmer air in fresh food compartment 12 across a coil or tubes of evaporator 212 that carries relatively colder refrigerant liquid and vapor mixture. The temperature in each compartment 12 and 14 can be monitored by a temperature sensor (not shown).

Flows 232 and 235 of saturated refrigerant vapor from each evaporator 212 and 214 are combined using a junction or combing device 220. This combined flow 239 then flows back to compressor 202. The refrigerant may become superheated while exchanging heat with refrigerant in the first reducing device 206 and/or second reducing device 210 through heat exchanger 207. From compressor 202, the cycle is repeated as previously described. Streams 232 and 235 may be at substantially the same pressure, e.g., such that streams 232 and 235 can be joined at junction 220 without necessarily using special devices such as a valve or Venturi. Heat exchanger 207 may be a location where tubing making up devices 206, 210 and flows 221 and 234 are located near or in contact with one another so as to promote the conduction of heat. Other configurations to exchange heat therebetween may be used as well.

FIG. 3 provides a schematic view of a phase separator 300 according to an exemplary embodiment of the present subject matter positioned within a mechanical chamber 302 of a cabinet 304. Phase separator 300 may be used in any suitable appliance or refrigeration system. For example, phase separator 300 may be used in refrigerator appliance 100 (FIG. 1) or refrigeration system 200 (FIG. 2) as phase separator 222. As discussed in greater detail below, phase separator 300 includes features for condensing refrigerant therein and for separating liquid and gaseous refrigerant.

As may be seen in FIG. 3, phase separator 300 includes a casing 310. Casing 310 may be constructed of or with any suitable material. For example, casing 310 may be constructed of or with metal tubing, such as half inch diameter copper or aluminum tubing. Casing 310 extends, e.g., linearly, between a top portion 312 and a bottom portion 314. The top and bottom portions 312 and 314 of casing 310 are spaced apart from each other, e.g., along a vertical direction V. Casing 310 also defines an interior volume. In particular, casing 310 defines a liquid refrigerant collection volume 318 at or adjacent bottom portion 314 of casing 310, and casing 310 also defines a gaseous refrigerant collection volume 320 at or adjacent top portion 312 of casing 310. Thus, gaseous refrigerant collection volume 320 may be positioned above liquid refrigerant collection volume 318 along the vertical direction V. The gaseous refrigerant collection volume 320 and liquid refrigerant collection volume 318 may also be contiguous within casing 310.

Casing 310 also has an outer surface 316 and an inner surface 317. Outer surface 316 and inner surface 317 are positioned opposite each other on casing 310. Inner surface 317 may assist with defining gaseous refrigerant collection volume 320 and/or liquid refrigerant collection volume 318.

A drying mechanism or element 330 is positioned within casing 310. In particular, drying element 330 is disposed between gaseous refrigerant collection volume 320 and liquid refrigerant collection volume 318 within casing 310. Drying element 330 is configured to remove water from the liquid phase refrigerant passing through or across drying element 330 into liquid refrigerant collection volume 318, e.g., from gaseous refrigerant collection volume 320. As an example, drying element 330 may be a desiccant, such as desiccant beads, that removes water from liquid phase refrigerant. It should be understood that other materials or elements may be used for drying element 330 as well. A pair of perforated metal screens 334 support drying element 330, e.g., trap drying element 330 therebetween. It should be understood that phase separator 300 need not include both of perforated metal screens 334. Thus, phase separator 300 may have a single perforated metal screen in alternative exemplary embodiments, and drying element 330 may be supported between the single perforated metal screen at a top of drying element 330 and filter 332 at a bottom of drying element 330.

Phase separator 300 is also equipped with a filter 332. Filter 332 may be positioned at or adjacent bottom portion 314 of casing 310. In particular, filter 332 may be positioned adjacent drying element 330 and/or one of screens 334. Filter 332 is configured to remove contaminants such as sediment, particles, or other materials from liquid phase refrigerant flow therethrough that could e.g., damage compressor 202 or foul other components of refrigeration system 200. As an example, filter 332 could be configured as a mesh or screen with small openings that block the flow of contaminants while allowing the flow of refrigerant.

Phase separator 300 also includes a refrigerant inlet conduit 322, a liquid refrigerant outlet conduit 324 and a gaseous refrigerant outlet conduit 326. Refrigerant inlet conduit 322 is configured for directing refrigerant into casing 310. In particular, refrigerant inlet conduit 322 may extend between compressor 202 of refrigeration system 200 (FIG. 2) and gaseous refrigerant collection volume 320 through casing 310, e.g., at top portion 312 of casing 310. An outlet 323 of refrigerant inlet conduit 322 is disposed within or at gaseous refrigerant collection volume 320. Refrigerant from compressor 202 exits refrigerant inlet conduit 322 at outlet 323 of refrigerant inlet conduit 322 and flows into gaseous refrigerant collection volume 320. Outlet 323 of refrigerant inlet conduit 322 may be positioned within gaseous refrigerant collection volume 320 such that outlet 323 of refrigerant inlet conduit 322 is positioned about one inch from (e.g., a top) one of screens 334 or perforated metal disk.

Gaseous refrigerant outlet conduit 326 is configured for directing gaseous refrigerant out of gaseous refrigerant collection volume 320. Thus, an inlet 327 of gaseous refrigerant outlet conduit 326 is positioned within gaseous refrigerant collection volume 320, e.g., at or adjacent top portion 312 of casing 310. Inlet 327 of gaseous refrigerant outlet conduit 326 may be positioned above outlet 323 of refrigerant inlet conduit 322 within gaseous refrigerant collection volume 320. Gaseous refrigerant outlet conduit 326 may extend between gaseous refrigerant collection volume 320 and condenser 204 of refrigeration system 200 (FIG. 2) through casing 310.

Liquid refrigerant outlet conduit 324 is configured for directing liquid refrigerant out of liquid refrigerant collection volume 318. Thus, an inlet 325 of liquid refrigerant outlet conduit 324 is positioned within liquid refrigerant collection volume 318, e.g., at or adjacent bottom portion 314 of casing 310. Inlet 325 of liquid refrigerant outlet conduit 324 may be positioned below outlet 323 of refrigerant inlet conduit 322 within casing 310. Liquid refrigerant outlet conduit 324 may extend between liquid refrigerant collection volume 318 and second reducing device 210 of refrigeration system 200 (FIG. 2) through casing 310.

A plurality of cooling fins 328 are positioned at or on outer surface 316 of casing 310, e.g., at top portion 312 of casing 310. Cooling fins 328 may be positioned on outer surface 316 of casing 310 such that cooling fins 328 are positioned opposite gaseous refrigerant collection volume 320 of casing 310. Cooling fins 328 may be mounted to casing 310 and extend away, e.g., radially, from outer surface 316 of casing 310. Cooling fins 328 may be constructed of or with any suitable material, such as a thermally conductive material including aluminum or copper. As an example, cooling fins 328 may be formed from a continuous strip of aluminum and wrapped about casing 310. Cooling fins 328 can assist with rejecting heat from refrigerant within casing 310, as discussed in greater detail below.

Phase separator 300 can assist with partially condensing a volume of refrigerant therein and can also separate liquid and gaseous refrigerant therein. For example, compressor 202 of refrigeration system 200 may be operated to increase a pressure of a refrigerant. The compressed refrigerant from compressor 202 is directed into phase separator 300 via refrigerant inlet conduit 322. In particular, the compressed refrigerant from compressor 202 may be directed into gaseous refrigerant collection volume 320 of casing 310. The compressed refrigerant may enter phase separator 300 as a superheated vapor. Refrigerant within gaseous refrigerant collection volume 320 of casing 310 may reject heat and a portion of the refrigerant may condense, e.g., on inner surface 317 of casing 310. Cooling fins 328 may assist with transferring heat from refrigerant within casing 310 to ambient air about casing 310 to assist with partially condensing the volume of refrigerant within casing 310. In such a manner, a volume of liquid refrigerant and a volume of gaseous refrigerant may be disposed within phase separator 300. The liquid refrigerant may flow down inner surface 317 of casing 310 into liquid refrigerant collection volume 318. In addition, the liquid refrigerant may flow through drying element 330 and filter 332 to remove water and debris from the liquid refrigerant, respectively. The gaseous refrigerant may rise and collect within gaseous refrigerant collection volume 320. The liquid refrigerant within liquid refrigerant collection volume 318 may be directed out of phase separator 300, e.g., to second reducing device 210 of refrigeration system 200 (FIG. 2), via liquid refrigerant outlet conduit 324, and the gaseous refrigerant within gaseous refrigerant collection volume 320 may be directed out of phase separator 300, e.g., to condenser 204 of refrigeration system 200 (FIG. 2), via gaseous refrigerant outlet conduit 326.

To assist with separating gaseous and liquid refrigerant within phase separator 300, casing 310 may be positioned and oriented such that liquid refrigerant within gaseous refrigerant collection volume 320 flows downwardly along the vertical direction V into liquid refrigerant collection volume 318, e.g., due to gravity. For example, inner surface 317 of casing 310 may slope downwardly at an angle α, e.g., relative to a horizontal axis. The angle α may be any suitable angle. For example, the angle α may be greater than thirty degrees and less than ninety degrees. As another example, the angle α may be greater than forty-five degrees and less than seventy-five degrees.

It should be noted that phase separator 300 may be used in a variety of other types of refrigeration systems in addition to those described above.

FIG. 4 provides a schematic view of a phase separator 400 according to another exemplary embodiment of the present subject matter positioned within a mechanical chamber 402 of a cabinet 404. Phase separator 400 may be used in any suitable appliance or refrigeration system. For example, phase separator 400 may be used in refrigerator appliance 100 (FIG. 1) or refrigeration system 200 (FIG. 2) as phase separator 222. Phase separator 400 includes similar features and may be constructed in a similar manner to phase separator 300 (FIG. 3).

As may be seen in FIG. 4, phase separator 400 includes a casing 410. Casing 410 extends between a top portion 412 and a bottom portion 414. Casing 410 defines a liquid refrigerant collection volume 418 at or adjacent bottom portion 414 of casing 410, and casing 410 also defines a gaseous refrigerant collection volume 420 at or adjacent top portion 412 of casing 410. Casing 410 also has an outer surface 416.

A drying mechanism or element 430 is positioned within casing 410. In particular, drying element 430 is disposed between gaseous refrigerant collection volume 420 and liquid refrigerant collection volume 418 within casing 410. A pair of perforated metal screens 434 support drying element 430, e.g., trap drying element 430 therebetween. Phase separator 400 is also equipped with a filter 432. It should be understood that phase separator 400 need not include both of perforated metal screens 434. Thus, phase separator 400 may have a single perforated metal screen in alternative exemplary embodiments, and drying element 430 may be supported between the single perforated metal screen at a top of drying element 430 and filter 432 at a bottom of drying element 430.

Phase separator 400 also includes a refrigerant inlet conduit 422. Refrigerant inlet conduit 422 is configured for directing refrigerant into casing 410. In particular, refrigerant inlet conduit 422 may extend between compressor 202 of refrigeration system 200 (FIG. 2) and gaseous refrigerant collection volume 420 through casing 410.

As may be seen in FIG. 4, refrigerant inlet conduit 422 extends through casing 410 at bottom portion 414 of casing 410. Refrigerant inlet conduit 422 also extends through liquid refrigerant collection volume 418 and drying element 430. An outlet 423 of refrigerant inlet conduit 422 is disposed within gaseous refrigerant collection volume 420. By extending refrigerant inlet conduit 422 through liquid refrigerant collection volume 418, refrigerant within liquid refrigerant collection volume 418 may be heated by refrigerant within refrigerant inlet conduit 422 prior to exiting liquid refrigerant collection volume 418.

It should be noted that phase separator 400 may be used in a variety of other types of refrigeration systems in addition to those described above.

FIG. 5 provides a schematic view of a phase separator 500 according to another exemplary embodiment of the present subject matter positioned within a mechanical chamber 502 of a cabinet 504. Phase separator 500 may be used in any suitable appliance or refrigeration system. For example, phase separator 500 may be used in refrigerator appliance 100 (FIG. 1) or refrigeration system 200 (FIG. 2) as phase separator 222. Phase separator 500 includes similar features and may be constructed in a similar manner to phase separator 300 (FIG. 3).

As may be seen in FIG. 5, phase separator 500 includes a casing 510. Casing 510 extends between a top portion 512 and a bottom portion 514. Casing 510 defines a liquid refrigerant collection volume 518 at or adjacent bottom portion 514 of casing 510, and casing 510 also defines a gaseous refrigerant collection volume 520 at or adjacent top portion 512 of casing 510. Casing 510 also has an outer surface 516.

Phase separator 500 also includes a refrigerant inlet conduit 522. Refrigerant inlet conduit 522 is configured for directing refrigerant into casing 510. In particular, refrigerant inlet conduit 522 may extend between compressor 202 of refrigeration system 200 (FIG. 2) and gaseous refrigerant collection volume 520 through casing 510.

As may be seen in FIG. 5, refrigerant inlet conduit 522 is mounted, e.g., brazed, to outer surface 516 of casing 510 at bottom portion 514 of casing 510. Refrigerant inlet conduit 522 also extends through casing 510 at top portion 512 of casing 510. An outlet 523 of refrigerant inlet conduit 522 is disposed within gaseous refrigerant collection volume 520. By mounting refrigerant inlet conduit 522 to casing 510 adjacent liquid refrigerant collection volume 518, refrigerant within liquid refrigerant collection volume 518 may be heated by refrigerant within refrigerant inlet conduit 522 prior to exiting liquid refrigerant collection volume 518.

It should be noted that phase separator 500 may be used in a variety of other types of refrigeration systems in addition to those described above.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. A sealed system, comprising: a compressor; a phase separator disposed downstream of the compressor, the phase separator comprising a casing having a top portion and a bottom portion, the casing defining a liquid refrigerant collection volume at the bottom portion of the casing and a gaseous refrigerant collection volume at the top portion of the casing, the casing also having an outer surface; a refrigerant inlet conduit extending between the compressor and the gaseous refrigerant collection volume; a gaseous refrigerant outlet conduit having an inlet positioned within the gaseous refrigerant collection volume of the casing; a liquid refrigerant outlet conduit having an inlet positioned within the liquid refrigerant collection volume of the casing; and a plurality of cooling fins positioned on the outer surface of the casing at the top portion of the casing.
 2. The sealed system of claim 1, further comprising a condenser disposed downstream of the phase separator, the gaseous refrigerant outlet conduit extending between the gaseous refrigerant collection volume of the casing and the condenser.
 3. The sealed system of claim 2, further comprising a first expansion device disposed downstream of the condenser such that the condenser is in fluid communication with the first expansion device, the first expansion device configured for reducing a pressure of refrigerant therein.
 4. The sealed system of claim 3, further comprising a first evaporator disposed downstream of the first expansion device such that the first expansion device is in fluid communication with the first evaporator.
 5. The sealed system of claim 3, further comprising a second expansion device disposed downstream of the phase separator, the liquid refrigerant outlet conduit extending between the liquid refrigerant collection volume of the casing and the second expansion device.
 6. The sealed system of claim 5, further comprising a second evaporator disposed downstream of the second expansion device such that the second expansion device is in fluid communication with the second evaporator.
 7. The sealed system of claim 1, wherein gaseous refrigerant entering the phase separator from the compressor partially condenses within the gaseous refrigerant collection volume of the casing, the casing positioned and oriented such that liquid refrigerant within the gaseous refrigerant collection volume of the casing flows downwardly into the liquid refrigerant collection volume of the casing.
 8. The sealed system of claim 1, further comprising a drying element positioned within the casing and disposed between the gaseous refrigerant collection volume and the liquid refrigerant collection volume.
 9. The sealed system of claim 8, wherein the refrigerant inlet conduit extends through the casing at the bottom portion of the casing, the refrigerant inlet conduit also extending through the liquid refrigerant collection volume of the casing and the drying element, an outlet of the refrigerant inlet conduit disposed within the gaseous refrigerant collection volume of the casing.
 10. The sealed system of claim 8, wherein the refrigerant inlet conduit is mounted to outer surface of the casing at the bottom portion of the casing and extends through the casing at the top portion of the casing, an outlet of the refrigerant inlet conduit disposed within the gaseous refrigerant collection volume of the casing.
 11. The sealed system of claim 1, wherein the cooling fins of the plurality of cooling fins are positioned opposite the gaseous refrigerant collection volume of the casing.
 12. A refrigerator appliance, comprising: a cabinet that defines a freezer chamber and a fresh food chamber; a sealed system configured for cooling the freezer chamber and the fresh food chamber, the sealed system comprising a compressor; a phase separator disposed downstream of the compressor, the phase separator comprising a casing having a top portion and a bottom portion, the casing defining a liquid refrigerant collection volume at the bottom portion of the casing and a gaseous refrigerant collection volume at the top portion of the casing, the casing also having an outer surface; a refrigerant inlet conduit extending between the compressor and the gaseous refrigerant collection volume; a gaseous refrigerant outlet conduit; a liquid refrigerant outlet conduit; a plurality of cooling fins positioned on the outer surface of the casing at the top portion of the casing a condenser disposed downstream of the phase separator, the gaseous refrigerant outlet conduit extending between the gaseous refrigerant collection volume of the casing and the condenser; a first expansion device disposed downstream of the condenser such that the condenser is in fluid communication with the first expansion device, the first expansion device configured for reducing a pressure of refrigerant therein; a freezer evaporator positioned adjacent the freezer chamber of the cabinet and disposed downstream of the first expansion device such that the first expansion device is in fluid communication with the freezer evaporator; a second expansion device disposed downstream of the phase separator, the liquid refrigerant outlet conduit extending between the liquid refrigerant collection volume of the casing and the second expansion device; and a fresh food evaporator positioned adjacent the fresh food chamber of the cabinet and disposed downstream of the second expansion device such that the second expansion device is in fluid communication with the fresh food evaporator.
 13. The refrigerator appliance of claim 12, wherein gaseous refrigerant entering the phase separator from the compressor partially condenses within the gaseous refrigerant collection volume of the casing, the casing positioned and oriented such that liquid refrigerant within the gaseous refrigerant collection volume of the casing flows downwardly into the liquid refrigerant collection volume of the casing.
 14. The refrigerator appliance of claim 12, wherein the phase separator further comprises a drying element positioned within the casing and disposed between the gaseous refrigerant collection volume and the liquid refrigerant collection volume.
 15. The refrigerator appliance of claim 14, wherein the refrigerant inlet conduit extends through the casing at the bottom portion of the casing, the refrigerant inlet conduit also extending through the liquid refrigerant collection volume of the casing and the drying element, an outlet of the refrigerant inlet conduit disposed within the gaseous refrigerant collection volume of the casing.
 16. The refrigerator appliance of claim 14, wherein the refrigerant inlet conduit is mounted to outer surface of the casing at the bottom portion of the casing and extends through the casing at the top portion of the casing, an outlet of the refrigerant inlet conduit disposed within the gaseous refrigerant collection volume of the casing.
 17. The refrigerator appliance of claim 12, wherein the cooling fins of the plurality of cooling fins are positioned opposite the gaseous refrigerant collection volume of the casing.
 18. A method for operating a sealed system, comprising: operating a compressor of the sealed system to increase a pressure of a refrigerant; directing compressed refrigerant from the compressor of the sealed system to a phase separator of the sealed system; partially condensing refrigerant within the phase separator of the sealed system; collecting liquid refrigerant within a liquid refrigerant collection volume of the phase separator and gaseous refrigerant within a gaseous refrigerant collection volume of the phase separator; directing liquid refrigerant from the liquid refrigerant collection volume of the phase separator to an expansion device of the sealed system; and directing gaseous refrigerant from the gaseous refrigerant collection volume of the phase separator to a condenser of the sealed system. 